Why Some Plastic Parts Fail After Passing All Tests: The Mass-Production Stability Gap
In a post-mortem meeting, there’s one sentence that shows up like clockwork: “Didn’t we pass all the tests?” On paper, everything looks perfect. Test reports are complete. Key metrics are within spec. Prototype parts were delivered smoothly. Yet once the product enters real use or sustained mass production, problems still surface—warpage, cracking, dimensional drift, unstable […]